P H O T O V O LTA I C M A N U A L

Solargen

Please read these instructions before installing or commissioning. This Solar Photovoltaic system should only be installed by a competent person. PLEASE LEAVE THESE INSTRUCTIONS WITH THE USER FOR SAFE KEEPING.
BAXI Heating UK Ltd 2011

Index
Index.........................................................................................................................3 Table Index................................................................................................................ 4 Figure Index..............................................................................................................5 Safety information.....................................................................................................6 1.INTRODUCTION...................................................................................................8 1.1.Preface...............................................................................................................8 1.2.Supply and Packaging........................................................................................8 1.3.Security Warnings...............................................................................................8 1.4.Installation Standards.........................................................................................8 1.4.1. Safety and Care..............................................................................................9 2.KIT CONTENTS.................................................................................................. 10 3.PV KIT INSTALLATION....................................................................................... 11 3.1.PV module........................................................................................................11 3.1.1.Choosing the site...........................................................................................11 3.1.2.Installation guidelines..................................................................................... 11 3.1.3.Mechanical characteristics.............................................................................. 11 3.1.4 Mechanic Installation.....................................................................................11 3.2.PV Generator....................................................................................................12 3.2.1.PV series connection.....................................................................................12 3.2.2.PV module fastening...................................................................................... 12 3.3.DC Electric Box (available as an optional extra)............................................... 13 3.3.1.Components.................................................................................................... 13 3.3.2.Location.......................................................................................................... 13 3.3.3.Electric Scheme.............................................................................................13 3.3.4.Crimp connectors........................................................................................... 13 3.4.Inverter..............................................................................................................14 3.4.1.Installation requirements................................................................................ 14 3.4.2.Clearances..................................................................................................... 14 3.4.3.Position..........................................................................................................14 3.4.4.Mounting the inverter.....................................................................................15 3.4.5.Connecting PV strings to the inverter............................................................. 15 3.5. AC electric box (available as an optional extra)...............................................16 3.5.1.Description.....................................................................................................16 3.5.2.Location.......................................................................................................... 16 3.5.3.Single line diagram......................................................................................... 16 3.6.Connection to the grid....................................................................................... 16 3.6.1.AC cable size.................................................................................................16 3.7.Energy meter..................................................................................................... 17 3.7.1.Warnings........................................................................................................17 3.7.2.Environmental requirements..........................................................................17 3.7.3.Cabling........................................................................................................... 17 3.7.4.Cable specification......................................................................................... 17 3.7.5.Installation data.............................................................................................. 17 3.7.6.Dimensions and mounting.............................................................................. 17 3.8.Electrical diagrams............................................................................................ 18 4.PV SYSTEM PROTECTION................................................................................ 19 4.1.Protection against lightening............................................................................. 19 4.1.1.Array Frame Earthing Decision Tree.............................................................. 19 4.2.Protection against direct contact....................................................................... 20 4.3.Protection against indirect contact....................................................................20 4.4.Warning and note signs..................................................................................... 20 4.4.1.Location of the safety labels........................................................................... 20 5.PV SYSTEM COMMISSIONING.......................................................................... 21 5.1.Connect a PV system........................................................................................ 21 5.2.Disconnect the PV system................................................................................ 21 5.3.Security notes...................................................................................................21 6.MAINTENANCE MANUAL................................................................................. 22 6.1.General information.......................................................................................... 22 6.2.PV generator.................................................................................................... 22 6.3.Inverter............................................................................................................. 22 6.3.1.Safety Warnings............................................................................................ 22 6.3.2.Inverter operation conditions......................................................................... 22 7.SUPPORTING STRUCTURE ASSEMBLING MANUAL....................................23 7.1.Flat roof............................................................................................................ 26 7.2.Parallel to pitched roof...................................................................................... 26
Baxi Heating UK Ltd 2011. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any retrieval system of any nature (including in any database), in each case whether electronic, mechanical, recording or otherwise, without prior written permission of the copyright owner, except for permitted fair dealing under Copyrights, Designs and Patents Act 1988. Applications for the copyright owners permission to reproduce or make other use of any part of this publication should be made, giving any details of the proposed use to the following address: The Company Secretary, Baxi Heating UK Ltd, Brooks House, Coventry Road, Warwick CV34 4LL. Full acknowledgement of author and source must be given. WARNING: Any person who does any unauthorised act in relation to a copyright work may be liable to criminal prosecution and civil claims for damages. Solargen solar PV

8.WARRANTY........................................................................................................29 9.MAINTENANCE..................................................................................................30 10.NOTES..............................................................................................................31

Table index
Index
10 Table 1. Equipment contained within the photovoltaic kit................................... 10 Table 2. Equipment available as an optional extra............................................. Table 3. Mechanical specifications.....................................................................11 14 Table 4. Inverter installation Minimum distances............................................. Table 5. AC cable cross sections.......................................................................16 18 Table 6. Relation between the kits and the inverter power................................ 20 Table 7. Maximum earth resistance.................................................................... 23 Table 8. Spacing between A-frames.................................................................. Table 9. Spacing between the roof supports..................................................... 27

Solargen solar PV

Figure index
Index
Figure 1. Handling.................................................................................................9 11 Figure 2. Fastening the modules to the roof mountings....................................... Figure 3. Modules physical dimensions..............................................................11 11 Figure 4. Module Fixing........................................................................................ Figure 5. Cable Routing.......................................................................................11 12 Figure 6. PV module junction box........................................................................ 12 Figure 7. PV series connection............................................................................ Figure 8. Diagram for the modules ground connection......................................12 Figure 9. Example of PV mounting......................................................................12 13 Figure 10. DC Electric Box..................................................................................... 13 Figure 11. DC Electric Box location....................................................................... 13 Figure 12. Correct crimping pliers.......................................................................... 13 Figure 13. Example of a single line scheme for the DC Electric Box..................... 14 Figure 14. Inverter installation requirements....................................................... 14 Figure 15. Minimum distances............................................................................... 14 Figure 16. Mounting position.................................................................................. 15 Figure 17. Mounting the inverter............................................................................ 15 Figure 18. Connecting PV strings to the inverter................................................... 16 Figure 19. AC electric Box..................................................................................... 16 Figure 20. Example of a single line diagram of the AC electric box....................... 17 Figure 21. Energy meter......................................................................................... 17 Figure 22. Meter terminal layout............................................................................ 17 Figure 23. Meter fixing points................................................................................. Figure 24. 1.32 - 2.64 kWp unifilar electrical diagram............................................18 Figure 25. 3.96 kWp unifilar electrical diagram......................................................18 Figure 26. Ex. electrical diagram with AC and DC electrical box...........................18 19 Figure 27. PV system protection............................................................................ 19 Figure 28. Array Frame earthing decision tree...................................................... 20 Figure 29. Safety Labels........................................................................................ 20 Figure 30. Warning Sign Injury or death risk....................................................... 21 Figure 31. PV system startup steps....................................................................... 21 Figure 32. Steps for the string disconnection from the inverter.............................. 22 Figure 33. Operational state of the inverter........................................................... 23 Figure 34. A-frame assembly................................................................................. Figure 35. A-frame mounting................................................................................ 23 23 Figure 36. Spacing between A frame profiles........................................................ 24 Figure 37. Transverse profile mounting................................................................. 24 Figure 38. A frame bracing.................................................................................... Figure 39. PV module centre clamp......................................................................24 25 Figure 40. PV module side clamps & plastic end caps.......................................... 25 Figure 41. Typical structure..................................................................................... 25 Figure 42. Profile connections............................................................................... 26 Figure 43. Anchors for flat tiles............................................................................. Figure 44. Anchors for mechanical tiles................................................................26 Figure 45. Anchors fixed on a pitched roof...........................................................26 Figure 46. Standard Mounting kit for portrait installations.....................................27 Figure 47. Standard Mounting kit Landscape accesory for Lands. installations...27 Figure 48. Transverse profile mounting to the roof brackets.................................27 Figure 49. PV module centre clamps....................................................................27 27 Figure 50. PV modules side clamps...................................................................... Figure 51. End covers for the transverse profiles..................................................28 28 Figure 52. Structure for 2 PV modules.................................................................. 28 Figure 53. Profile connectors................................................................................

Solargen solar PV

Safety information
In order to reduce the number of deaths and major accidents attributable to work at height, the health and Safety Executive has introduced comprehensive regulations and guidance that should be followed by all businesses working at height. We consider in the following paragraphs some of the main features of the regulations and guidance. This is, however, only a limited summary and it is recommended that all businesses planning on undertaking solar PV installations obtain a copy of the regulations and guidance issued by the Health and Safety Executive and carefully consider the contents. The regulations and guidance state that you are required to carry out a risk assessment for all work conducted at height and to put in place arrangements for: Eliminating or minimising risks from work at height. Safe systems of work for organising and performing work at height. Safe systems for selecting suitable work equipment. Safe systems for protecting people from the consequences of work at height. The regulations and guidance highlight a hierarchy for safe work at height: Avoid the risk by not working at height if practicable. Prevent falls, where it is not reasonably practicable to avoid work at height; you are required to take suitable and sufficient steps to prevent the risk of a fall including selecting the most suitable work equipment (in accordance with the regulations). Mitigate the consequences of a fall; where tha risk of a person or object falling still remains, take suitable and sufficient measures to minimise the distance and consequences of any fall. Collective protection measures, such as guard rails on scaffold, should be given priority over personal protection measures, such as safety harnesses. Within the regulationsframework, you are required to: 1) Assess the risk to help you decide how work safely. 2) Follow the hierarchy for safe work at height (i.e.avoid, prevent and mitigate). 3) Plan and organise your work properly, taking account of weather conditions and the possibility of emergencies. 4) Make sure those working at height are competent. 5) Make use of appropriate work equipment. 6) Manager the risks from working on or around fragile surfaces and from falling objects. 7) Inspect and maintain the work equipament to be used and inspect the place where the work will be carried out ( including access and egress). When preparing to install a solar Photovoltaic system, it is required that you perform a risk assessment in relation to work at height and plan how you will organise your work, taking into account the site, the weather conditions and the experience and competence of colleagues or and the experience and competence of colleagues or contractors who may be working at height with you. Risk Assessments The HSE has published a number of very useful free publications that advise how to undertake risk assessments. Two of these that you should obtain are: Five Steps to Risk Assessment. A Guide to Risk Assessment Requirements. The five steps outlined in the HSE leaflet are: Step 1: Look for the hazards This will mean looking at the site and identifying significant hazards. These could be features such as a steep roof, a fragile surface where the collectors may be mounted, unecen ground or obstructions where access to the roff might be required.

Solargen solar PV

Safety information
Step 2: Decide who may be harmed and how This might mean considering the particular risks that young workers or trainees might face and thinking about the residents of the household or visitors who could be hurt by your activities. Step 3: Evaluate the risks and decide which precautions should be made. You should consider how likely it is that each hazard will cause harm, decide which precautions you might take and then assess, after you have taken those precautions, whether the remaining risk will be high, medium or low.Where you identify remaining risks, you should consider which further action you could take to control the risks so thar harm is unlikely. Step 4: Record your findings If you have fewer than five employees you do not need to write anything down, though it is useful to keep a written record of what you have done. If you employ five or more people you must record the significant findings of your assessment. You must also tell your employees about your findings. You need to be able to show that a proper check was made, that you considered who might be affected, that you dealt with all the obvious significant hazzards, that the precautions you propose are reasonable and that the remaining risk is low. Step 5: Review your assessment if necessary Each solar Photovoltaic installation may bring its own challenges and present its own particular hazards. You should therefore be careful no to rely on a standard risk assessment for installing a solar Photovoltaic system in a house, but at the preparation stage you should consider where scaffold or other access equipament might be positioned and look out for any obvious obstacles to this, such as a conservatory or porch. In addition to the risks associated with work at height, you should also consider the risks associated with lifting and carrying solar collectors, using electric drills and using blow lamps or blow torches for soldering. This is not an exclusive list and you should consider all aspects

Solargen solar PV

1. INTRODUCTION
1.1. Preface

Attention The installation of this photovoltaic kit must only be performed by people qualified to the current standards and who are competent to do so. Any solar PV system must comply with heath & safety requirements, BS7671 and other relevant standards & codes of practice (working at heights etc). Other standards which must be adhered to are: Engineering Recommendation G83/1 (2003) Recommendations for the connection of small scale embedded generators (up to 16A per phase) in parallel with the public low voltage distribution networks IEE Guidance Note 7 to BS7671 Special Locations, section 12 Solar Photovoltaic (PV) Power Supply Systems (ISBN 0 8596 995 3, 2003) This manual is not intended to replace any best practice guides such as Photovoltaics in Buildings Guide to the Installations of PV Systems published by the DTI or any other standards which maybe relevant which are in force at the time of writing. 1.2. Supply and Packaging The photovoltaic (PV) kit will be provided in a package properly developed for this purpose. This package contains the PV modules, inverter, generation meter, protection switch gear, solar cable, connectors and accessories suitable for use with the Baxi roof mountings supplied. The profiles are packaged apart, due to their length. The package should be transported upright and fixed, in order to eliminate any chance of slips and shocks, to avoid damage to the equipment. Please ensure no materials are placed on top of the packaging. 1.3. Security Warnings DANGER Risk of death due to high voltages inside the inverter All works on the PV System should be performed only by someone qualified to do so, in accordance with CURRENT REGULATIONS & standards. CAUTION Risk of burns due to hot parts of the inverter housing Do not touch the inverter housing during operation. PV MODULE EARTH CONNECTION Take into account regulations for earth connection. It is advised to connect all exposed metal parts, including the PV frames to ground via appropriate methods suitable in accordance with BS 7671 current edition. 1.4. Installation Standards The PV system should be installed in accordance with the current electrical regulations; BS7671. All the safety standards and regulations in force should be known at the time of installation. Baxi Heating UK are not responsible for any damage to the equipment during installation works.. The PV modules should be carefully installed; predicting possible adverse weather conditions which may causes difficulties with the installation, i.e. high winds & rain. PV modules should be installed facing true South where possible in order to obtain maximum electrical generation. Slight deviation from South can be acceptable; this should be checked by a competent person before commencing with the installation.

Solargen solar PV

1. INTRODUCTION
1.4.1. Safety and Care During the installation, the following operation and maintenance recommendations when handling the photovoltaic modules must be taken in consideration: 1. 2. 3. It is recommended to maintain the modules properly packaged, inside the box, on its transport pallet, until the moment of installation. The front surface of the photovoltaic module should remain covered with an opaque material until all connections are established and verified. When exposed to sunlight or other light source, the module produces electricity (in DC current); the association in series of 2 or more modules produces enough energy to cause fatalities from electrocution in case of contact with active parts of the electrical circuit. Do not touch the terminals of the connectors when the module is exposed to light sources; take precautions to avoid the contact with voltages equal to or higher than 30 Volts DC; the installer should not forget that a string of modules associated in series will have a total voltage equal to the sum of the individual voltages of the modules. Use appropriate tools for electrical work in installation and maintenance operations. Do not disconnect the wires from the module while it is working; the risk of accident is very high due to the electric arcs generated, and it may also damage the product. The modules should only be connected in a dry place with favorable climatic conditions. DO NOT walk on the module(s), DO NOT place loads on their surfaces, DO NOT drop objects on the module, DO NOT knock on the module with any object. When handling, prevent the dropping of modules; a module with broken glass cannot be used or repaired. The module should always be moved by two people and seized by the aluminum frame, as shown in (Figure 1). Keep the module away from objects that could damage it. Do not install the module near flammable materials, for example fuel tanks or areas where there are flammable vapors; the connectors of the module, if poorly coupled, can generate electric arcs causing ignition of flammable materials; Keep flammable materials at a minimum distance of 30 cm between the active parts of the electrical installation, such as connectors or other connection points. Do not bend, damage or place loads on connecting cables and module connectors. Do not pierce the aluminum frame, glass or the back protection surface of the module; these actions will void the warranty. NEVER, under any circumstances, open the junction box of the photovoltaic module; besides the personal safety risk, exposing the electrical parts of an active photovoltaic module may compromise the proper functioning of the module. Verify that no other equipment in the facility may cause electrical or mechanical damage to the module. The installation, operation and maintenance of the module should be performed only by qualified personnel. Take actions to keep children or outsiders away from any element of the installation. Do not paint or paste any type of adhesive on the module. Do not dismantle or remove any part of the module. Do not use metal objects, jewelry and accessories during installation or maintenance of the module. When installing the module, be sure that the cables are always at the bottom of the junction box.

4.

5. 6. 7. 8. 9. 10. 11. 12.

13. 14. 15.

16. 17. 18. 19. 20. 21. 22.

Figure 1. Handling
Solargen solar PV

2. KIT CONTENTS

Table 1: Equipment contained within the photovoltaic kit

Image

Equipment

PV Module

Inverter

Energy meter

Supporting structure

4mm Solar Cable

Connectors

Main AC switch

Main DC switch

Table 2: Equipment available as an optional extra.

AC Electric Box

DC Electric Box

10

Solargen solar PV

3. PV KIT INSTALLATION
3.1. PV module 3.1.1. Choosing the site The installation site must obey the following points: The modules should be installed facing south The angle of orientation must be adequate to the site latitude. PV modules must not be shaded. Do not install the system near flammable products. 3.1.2. Installation guidelines Figure 2. Fastening the modules to the roof mountings The modules should be properly fastened to the supporting structure, to be able to withstand wind and snow accumulation. This should be done only with the equipment supplied and cabling facing downright. (Figure 2) The module assembly must be in accordance with the procedures described in the PV module installation manual. 3.1.3. Mechanical Characteristics
35 982

Table 3. Mechanical specifications

410

Module dimensions (LxWxH) Weight

1.639 mm 982 mm x 35 mm 20kg 60 polycrystalline 6 Inch Cells Tempered and Textured 4 mm Glass EVA (Ethylene Vinyl Acetate) PPE (Polyester Polyester Primer) Silver Anodized Aluminum 3 Bypass Diodes (16A) IP 65W/ 3 Bypass Diodes 2 Cables of 0,9 m w/ Tyco connectors

1229

Solar Cells Front Cover

Mechanical specifications
1639

Encapsulant Back Cover Frame Diodes Junction Box Cables

Figure 3. Modules physical dimensions

3.1.4. Mechanic Installation 1. 2. 3. 4. 5. Before starting the installation you must be fully equipped in order to perform the work safely. Check the instructions and precautions including those of the support structure. Do not perforate the structure or the module. The module should be installed with a minimum angle inclination of 1. The installation must be done with the Junction Box on the upper side of the module, as shown on the left picture (a); on the right picture (b), the modules were installed upside down, meaning that the breather of the Junction Box will be blocked, which will damage the module in the future; see ( Figure 4). Modules shall be mounted in order to guarantee that minimum 100 mm clearance between the module frames and the support shall be maintained to assure ventilation. The cable must not be bent or crushed on the direct exit of the cable screw joint; a minimum bending radius R, equal to or greater than the cable diameter multiplied by 5, must be maintained; the cable must be routed in a way that tensile stress on the conductor or connections is prevented see ( Figure 5).

a
Figure 4. Module Fixing

6. 7.

Figure 5. Cable Routing

Solargen solar PV

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3. PV KIT INSTALLATION
junction box 3.2. PV Generator 3.2.1. PV series connection The PV generator is a group of one or more PV modules connected in series, parallel or both. (Figure 6) The series connection of the PV modules is accomplished by connecting the positive connector to the negative connector of the following module.
(Figure 7)

Electrical installation
You should not use modules with different characteristics in the same installation. The maximum number of modules to be installed in series on the installation, N_(max), is calculated using the following formula: Figure 6. PV module junction box N_(max) = V_(Max System) / V_(OC (CTS))
+ -

+ -

The maximum voltage supported on an installation, with Baxis photovoltaic modules is 1000 (V) In Series connection

Figure 7. PV series connection

The resultant voltage of connecting two or more modules in series is the sum of individual voltages of each module. You should never connect a number of modules whose resultant voltage exceeds the maximum system voltage (Vsyst). Parallel connection The resultant electrical current of connecting two or more modules in parallel, is the sum of the individual electric currents in each module. Please use an external junction box to make the parallel connection between modules. Whenever more than 2 strings of modules in parallel are connected, each of those strings should be protected with a fuse that could cut the string in case of default. The value of the fuse must be 10 A or at maximum 12 A. A fuse must be used in each polarity. Grounding

2 3 4 5

For safety electrical reasons, the module frame and the installation must be grounded, to ensure the equipotentiality. This connection also ensures that any electric current leakage from the equipment will flow to the ground. The connection of the frame should be performed by clamping and should ensure the contact. MPrime recommends the use of suitable accessories for this purpose. In the frame there are 4 holes with a 4 mm diameter, indicating the earth symbol, to tighten the connectors of ground protection (see Fig 8). The section of the protective earth conductor must be equal to or greater than the section of the active conductor. The number of PV modules connected in series depends on the kW output of the inverter. 3.2.2. PV module fastening The PV modules should be mounted to frames or roof mountings supplied. No other frame is suitable for the mounting. (Figure 9)

Figure 8. Diagram for the modules ground connection

Figure 9. Example of PV mounting.

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Solargen solar PV

3. PV KIT INSTALLATION
3.3. DC Electric Box (available as an optional extra). 3.3.1. Components The DC Electric Box contains one type two overvoltage discharger for protection against indirect lightening strikes. (Figure 10) 3.3.2. Location The DC Electric Box should be placed at the input on the inverter. If the cable length between the PV generator and the inverter is longer than 10 m, an additional protection should be used next to the PV generator.
(Figure 11)

Figure 10. DC Electric Box

Figure 11. DC Electric Box location

3.3.3. Electric Scheme Figure 8 shows an example of a single line diagram of the DC switchboard. If the PV generator is composed of 3 or more strings, string fuses should be added to the DC Electric box. 3.3.4. Crimp connectors Figure 12. Correct crimping pliers When the crimping of connectors is needed to create whips, correct crimping pliers should be used. The left figure shows the pliers required to crimp the connectors. (Figure 12)

WIRING DIAGRAM
Earth Pin MG PE
WDU 10

HO7Z1-K

Earth wire 6mm

STRING 1

STRING 2

TYCO CONNECTORS

Wire RV-K 6mm Black PE

OK CHANGE OK CHANGE

OVP Weidmller Ref. 8882340001 TYCO CONNECTORS INVERTER

Figure 13. Example of a single line scheme for the DC Electric Box
Solargen solar PV

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3. PV KIT INSTALLATION
3.4. Inverter 3.4.1. Installation requirements (Figure 14) The location and type of installation should be adequate to the inverters dimensions and weight. It must be installed on a solid base. The installation should be always accessible (do not install in areas with limited access), and allow an easy removal of the equipment. The ambient temperature for operation should be between 25 and +60C. Do not place the inverter in direct sunlight. Power reduction and overheating can occur. Do not fasten directly to studded walls, use brick or block walls only.The inverter may produce noise during operation that may be considered a nuisance, site the inverter where vibration cannot cause any nuisance. 3.4.2. Clearances The clearances shown in table 3 should be observed to ensure heat dissipation and to have enough space to remove the Electronic Solar Switch. (Figure 15) 3.4.3. Position The inverter should be placed on a vertical wall. However, if strictly necessary, it can be installed at a maximum angle of 45. (Figure 16) Do not install the inverter: Figure 14. Inverter installation requirements Table 4. Inverter installation Minimum distances Minimum distance Sides Top Under Front 20 cm 20 cm 20 cm 5 cm On flammable materials Near places where highly flammable materials are stored Potentially explosive atmospheres

41 kg

Figure 15. Minimum distances

min 45

Install inverter in vertical position or tilted backwards with a maximum angle of 45 Figure 16. Mounting position
14
Solargen solar PV

Do not install inverter in horizontal or in forward tilted position

3. PV KIT INSTALLATION
3.4.4. Mounting the inverter Use of the support provided to install the inverter is recommended. For a vertical installation, the support should be mounted using 8mm x 50mm hexagonal head bolts & wall plugs supplied. (Figure 17) 1 Installation with stainless steel hexagonal head bolts and wall plugs; 2 Mark the three holes for the bolts with the template 3 Drill the holes and insert the wall plugs; 4 Install the top screws leaving 4mm protruding from the wall 5 Hook the inverter with the upper mounting slots on the rear panel, so as to introduce both splints in the openings at the upper end of the rear panel. Visual Inspection: The inverter is properly mounted, only if both splints are tucked into the rear panel openings. 6 Fasten the bottom bolt to prevent the removal. 7 Check the firm mounting of the inverter. Figure 17. Mounting the inverter 3.4.5. Connecting PV strings to the inverter. (Figure 18)

connection AC communication

Figure 18. Connecting PV strings to the inverter.

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3. PV KIT INSTALLATION
3.5. AC electric box (available as an optional extra). 3.5.1. Description The AC electrical panel consists of a surge protection of type II power surge from the grid or from the protective conductors. This will also consist of a circuit breaker for over current protection and a circuit breaker for indirect contact protection. (Figure 19) 3.5.2. Location The AC electric box should be installed as close as possible to the inverters AC output. 3.5.3. Single line diagram Figure 19. AC electric Box Figure 20 shows the single line diagram of the AC electric box.

PIN WPE 6mm PE

230 VAC 50 Hz
Wire HO7V-K 6mm yellow/green
2 2

INVERTER N
L1 PIN WDE 35mm
Wire HO7V-K 6mm blue Wire HO7V-K 6mm black
1 3
2 2

Thermal protector c shape 25A

L1
N 1 OK CHANGE

PE

ID 230V 40A 300 mA

R
N 2

OVP Weidmller Ref. 8859730000

PIN WDU 35 mm

L1

Figure 20. Example of a single line diagram of the AC electric box

ENERGY METER

Table 5. AC cable cross sections Cable cross section 4 mm 6 mm 10 mm 16 mm 25 mm 35 mm Maximun Length 1200 51 m 77 m 128 m 205 m 321 m 449 m 1700 38 m 57 m 95 m 152 m 238 m 333 m 2500 25 m 37 m 62 m 100 m 156 m 218 m 3300 16 m 25 m 41 m 66 m 104 m 146 m 3.6. Connection to the grid 3.6.1. AC cable size The connection to the inverter should be done with 3 core cable (L, N, E). The AC terminals for grid connection, included in the inverters package, allow the connection of a maximum cross section of 4 mm. Table 4 presents the maximum length of cables, according to the section and output power of the inverter.

Note: Considering 1% U (Voltage Drop)

16
Solargen solar PV

3. PV KIT INSTALLATION
3.7. Energy meter The meter provided in the PV kit is illustrated on the figure 21. 3.7.1. Warnings

DANGER OF ELECTRIC SHOCK Meters must be installed only by suitably-qualified personnel, observe the following safety advice. Ensure all activities are undertaken in accordance with the relevant electrical regulations. Before installing or removing a meter, or removing the terminal cover for any reason, isolate the meter from the mains supply by removing the supply-side fuses or using alternative local arrangements. Take appropriate measures to ensure that the isolation cannot be overridden by another person. For example, keep physical possession of the supply fuses. Clean meters only with a damp cloth or sponge. Do not use excessive or running water. Install meters in accordance with environmental specifications given in the installation information of the meter manual (P 25). Use only tools that have been approved for electrical installations. Do not install meters that are obviously damaged. Do not install meters that have been dropped or otherwise subjected to significant impact even if no damage can be seen. Following installation, ensure that the meter terminal covers are correctly fitted and sealed to prevent user access. Ensure that the meter supply cabling is isolated from the mains supply, and that the isolation cannot be overridden by another person. Following installation, ensure that the meter covers are correctly fitted and sealed to prevent user access. 3.7.2. Environmental requirements This meter is certified for indoor use only. Notes: The meter environment must provide sufficient ventilation to prevent overheating when the meter is operating at maximum current. The meter should not be positioned where it will be subject to direct sunlight. Operating environment: Temperature: -10C to +45C Humidity: 40% to 95% RH 3.7.3. Cabling The terminal layout and details of the mains connections are shown at Figure 17. For optional input/output connections details, refer to the connection diagram provided on the meter. The symbols used on the connection diagram are illustrated in the relevant topics in the Inputs and Outputs meter manual section (page 22). (Figure 22) Terminal Function 1- Live in 2- Neutral in 3- Neutral out 4- Live out 3.7.4. Cable specification Any cables used must be suitable for use in accordance with the electrical regulations, BS7671 current edition.
105 mm

Figure 22. Energy meter

Figure 22. Meter terminal layout

3.7.5. Installation data Cross sectional cable area: Maximum 35mm 3.7.6. Dimensions and mounting

5mm
25mm

52mm 130mm

52mm

The meter is provided with two fixing points located within the terminal area, which can be accessed only by removing the terminal cover.
(Figure 23)

Figure 23. Meter fixing points

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3. PV KIT INSTALLATION
3.8. Electrical diagrams The figure 24 and 25 shows the electrical diagrams for installation the Solar Photovoltaic system with the components provided in the PV kits. AC and DC electrical box are available as an optional accessory kit and in the figure 26 show the electrical diagram to install the Solar PV System.
Inverter

The table below links the inverter to use with the specified Denomination kit.

. . . .. . . .

Table 6. Relation between the kits and the inverter power Denomination KIT 1.32 kWp 1.76 kWp 2.64 kWp 3.96 kWp Collectors Number 6 8 12 18 Inverter SMA Sunny Boy 1200 SMA Sunny Boy 1700 SMA Sunny Boy 2500 SMA Sunny Boy 3300

Figure 24. 1.32 - 2.64 kWp Unifilar Electrical diagram

Inverter

Figure 25. 3.96 kWp Unifilar Electrical diagram

PV GENERATOR

Solar Cable 4mm

- +

- +

- +

- +

- +

+ -

LABEL 1 E.B.DC1 Detal1

SMA SB 1200

+ -

E.B.AC1

LABEL 3 LABEL 4

Detal2

LABEL 2

Installation in Loft

kWh

Generation Meter

LABEL 5

Main isolator ( Double pole) Securable in off position only New AC Installation Utility Meter kWh

DNO supply

Main Cosumer Unit LABEL 6+SCHEMATIC Existing House AC Installation

Figure 26. Example Electrical diagram with AC and DC electrical box.

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4. PV SYSTEM PROTECTION
In order to prevent damage to the system due to over currents (overload or short circuits) that might occur during use, measures for adequate protection should be taken. 4.1. Protection against lightening PV systems do not increase the buildings risk of being hit by lightning. Any earthing arrangements must be in accordance with BS-7430, BS-6651, BS-7671. If there is already a lightening protection system (LPS) in the building the PV generator must be connected to it. The internal protection circuit of the PV should be carefully implemented. Exceptions can be made to photovoltaic systems that are situated in exposed locations, which should have a proper separate protection system against lightening. If the building does not have an LPS the PV support structure should be connected to earth, and incorporated in equipotential bonding according to the figure 27. 4.1.1. Array Frame Earthing Decision Tree The kits are composed with class II modules, class II DC cables & connectors and are connected to the mains via an inverter with an isolation transformer. This approach is recommended and permits the array frame to be left floating. (Figure 28)

Figure 27. PV system protection

Yes

Class II modules? Class Il Cables, connectors/ions & Junction Boxes Isolation Transformer in Inverter?
(Note: to BS 3535 between a.c. & d.c.) and and

No In Equipotential Zone? Yes

(Note: freestanding ground mounted, or building roof mounted arrays (away from building metalwork) will normally not be within the equipotential zone. However, a solar thermal system, or other building linked metalwork, installed within reach may extend the equipotential zone outside the normal building envelope)

PME Earthing? Yes Leave Floating Install & bond to earth spike
(Note: do not take PME out of equipotential Zone) (Note: Use 10mm braid or equiv)

No

(Note: Use 10mm braid or equiv)

Bond direct to Consumer Earthing Terminal

(Note: If an earth spike is already Installed for Lightning Protection, bond to this braid) (Note: Use 10mm braid or equiv)

Figure 28. Array Frame earthing decision tree

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4. PV SYSTEM PROTECTION
4.2. Protection against direct contact The protection against direct contacts should be carried out by one or more of the following processes: Active part insulation Use of barriers or enclosures Use of low voltage security Use of reduced voltage protection The active parts must necessarily be isolated by the use of equipment that is in accordance with regulations in force and its proper implementation in the installation. The conductor extremities should be always well isolated, to ensure a protection higher than IP2X 4.3. Protection against indirect contact The protection against indirect contacts is based on the automatic cutting of the power, using a residual current device (RCD) connected to an appropriate protective earth system. (Table 7) 4.4. Warning and note signs All labels must be clear, easily visible, constructed and affixed to last and remain legible for the lifetime of the system. Table 7. Maximum earth resistance Earth resistance () R 100 In (mA) 300 PV Array d.c. Junction Box. Danger - contains live parts during daylight.
Label 1

Dual supply labeling should be provided at the service termination, meter position and all points of Isolation to indicate the presence of on site generation and indicating the position of the main a.c. switch disconnector. Requirements for labeling are contained within the relevant sections of this guide. The labels provided in the PV kit can be seen at Figure 29 and 30. 4.4.1. Location of the safety labels The PV installations should be labeled in the following way: Label 1 Array Junction Box Label 2 DC plugs and socket connectors - must be fixed next to connectors, except those that are inaccessible to anyone except trained personnel in the course of PV maintenance or fault finding. Label 3 DC Switch Label 4 Inverter

Do not disconnect d.c. plugs and sockets under loadturn o a.c. supply rst.
Label 2

PV array d.c. isolator. Danger - contains live parts during daylight.

Label 3

Inverter - Isolate a.c. and d.c. before carrying out work.

Label 4

Label 5 Main AC isolator Label 6 Dual supply label to be applied to the service termination, meter position and all points of isolation to indicate the presence of on site generation and the position of the main a.c.switch disconnector.
(See in the figure 24, figure 25, figure 26 the end location safety labels)

PV system-main a.c. isolator.

Label 5

Do not work on this equipment until it is isolated from both mains and on-site generation supplies

WARNING dual supply

Isolate on-site generator at Isolate mains supply at

Label 6

Figure 29. Safety Labels

Figure 30. Warning Sign Injury or death risk

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5. PV SYSTEM COMMISSIONING
5.1. Connect a PV system The system start up must only be performed by a qualified technician. To start up the PV system one should proceed as follows: 1 Assure that the inverter is not damaged due to shipping; 2 - Check the voltage of the PV generator in open circuit. This should not exceed the maximum admissible DC input voltage of the inverter; 3 Connect the positive terminal of the string to the positive string input of the inverter. Connect the negative terminal of the string to the negative string input of the inverter. CHECK THE POLARITY!!! 4 Not used DC plug connectors should be sealed with the proper sealing plugs; 5 Check the correct connection of the AC cable to the inverter; 6 Close the built in DC switch in the inverter; 7 Connect the AC circuit turning on the breaker on the PV electric box; 8 Check the display, to see if the inverter is in function mode, or if it is giving any kind of error. (Figure 31) Figure 31. PV system startup steps. Never disconnect the inverter from the PV installation before isolating from the AC voltage (on the electric box, open the breaker). 5.2. Disconnect the PV system Any works carried out on the PV system must only be done by a qualified technician. To disconnect the inverter from the PV generator, follow the procedures: 1 Turn off breaker on the AC electric Box; 2 Turn of breaker on the DC inverter; 3 Disconnect strings from the inverter.
(Figure 32)

3.

4.

5.3. Security notes PV modules produce electricity when exposed to daylight and individual modules cannot be switched off. Hence, unlike most other electrical installation work, the electrical installation of a PV system typically involves working on a live system. See requirements of Regulation 14 of Electricity at Work Regulations 1989. PV presents a unique combination of hazard due to risk of shock, falling and other simultaneous manual handling difficulty. All of these hazards are encountered as a matter of course on a building site, but rarely all at once. While roofers may be accustomed to minimising risks of falling or injury due to manual handling problems, they may not be used to dealing with the risk of electric shock. Similarly, electricians would be familiar with electric shock hazards but will not be used to handling large objects at heights.

Figure 32. Steps for the string disconnection from the inverter

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6. MAINTENANCE MANUAL
6.1. General information This document outlines all the relevant parameters for the correct functioning of the PV system. Additionally, the document includes maintenance instructions for the correct performance of the PV system. Pay close attention to the indications contained in this manual. The maintenance of the PV systems must be always undertaken by a competent person or persons. Pay attention to standards & regulations in force in order to prevent injury to persons or damage to equipment. The maintenance of a PV installation is mostly preventive than corrective. Maintenance should be carried out on an annual basis. 6.2. PV generator The PV modules should be visually inspected for any damage and then washed with a soap & water solution on an annual basis. Any mounting rails & brackets should be checked for tightness & adjusted accordingly. Maintenance must be undertaken using appropriate health & safety precautions. 6.3. Inverter In order to assure optimal performance, it should be checked regularly with different levels of solar irradiation to ensure optimisation of the system. Cleaning procedures on the inverter is only necessary if the heat dissipation is degraded due to dirt on the loops cover (arrowheads fan), fans, heat sinks, or the space between the inverter and the wall. The dirt should be carefully removed with a soft brush. If the status LEDs or display is not visible due to the dirt, clean with a damp cloth. Do not use solvents, abrasives or caustic substances. The maintenance of the inverter must be conducted according to the procedures described in the inverters manual. 6.3.1. Safety Warnings The opening of the inverter and Electric installation Repair Any works carried out on the inverter should only be performed by a competent person. Even without external voltage, high voltages can be produced inside the inverter. These high voltages can cause severe injury and death The temperature in some parts of the inverters case especially the temperature of the heat sinks can achieve, even during normal operation, values above 60 C. There is burning risk by touching hot components. 6.3.2. Inverter operation conditions The operational conditions are indicated by LEDs on the front part of the inverter, and by the built in display. For the LEDs to indicate an operational condition, the inverter must be connected on the DC side. There should be a minimum solar radiation to feed the inverter with the necessary voltage. (Figure 33) Operation Earth Fault Failure The homeowner should ensure that the LED is illuminated, if possible during different solar radiation conditions, especially in the first year of after installing the system. This way, it is possible to detect sizing or installation errors and ensure the proper operation of the PV system. When alarm signs are detected in the inverter, the equipment manual should be consulted in order to understand the possible issue and to help identify the solution.

Figure 33. Operational state of the inverter

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7. SUPPORTING STRUCTURE ASSEMBLING MANUAL

7.1. Flat roof Installation sequence The A-frame assembly should be clamped using the nuts & bolts supplied with the kit. (Figure 34)

Figure 34. A-frame assembly The mounting to the floor should be carried out using appropriate fixings for the substrate. If there are questions regarding to validity of the supporting surface or questions relating top safety then a qualified structural Engineer should be consulted. (Figure 35)

Figure 35. A-frame mounting The A-frame mounting should be performed, in a way that the spacing between them is: (Table 8, Figure 36). Table 8. Spacing between A-frames Structure 2 PV modules A-frame N 3 Spacing 732 mm Profile overhang 270 mm

Table 7

Figure 36. Spacing between A frame profiles

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7. SUPPORTING STRUCTURE ASSEMBLING MANUAL

The mounting of the transverse A frame profile is completed using a stainless steel M10 nuts & bolts (supplied). (Figure 37)

Figure 37. Transverse profile mounting

The A frames are braced using the 30x8mm profile, use the M10 nuts supplied. (Figure 38)

819 mm

Figure 38. A frame bracing

The centre clamps are fitted to the frame with M8 nuts & bolts (supplied).
(Figure 39)

Figure 39. PV module centre clamp

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7. SUPPORTING STRUCTURE ASSEMBLING MANUAL

The PV modules should be clamped to the sides of the frame using the side clamps & nuts & bolts supplied. The plastic end caps should then be pushed into the ends of the profiles. (Figure 40)

Figure 40. PV module side clamps & plastic end caps

The following figures present the typical supporting structures for flat roofs for 2 and 4 modules. (Figure 41)

Figure 41. Typical structure

To connect the A frames together use the connection profile piece connected with M10 stainless steel nuts & bolts (supplied). (Figure 42)

Figure 42. Profile connections

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7. SUPPORTING STRUCTURE ASSEMBLING MANUAL

7.2. Parallel to pitched roof Installation sequence The roof brackets supplied are suitable for use with a wide range of roof tiles. The brackets must be fixed to the roof rafter with appropriate fixings suitable for the rafter material. If the rafter is wood then it is advisable to pre drill the holes for the fixings to ensure the timber does not split. Ensure the drill used is smaller than the fixing to allow correct tightening of the fixing can be made. (Figure 43, Figure 44 and Figure 45)

Appropriate roofing material (eg Lead/ Felt )

Figure 43. Anchors for flat tiles.

Figure 44. Anchor for mechanical tiles (available as an accessory kit)

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Figure 45. Anchor fixed on a pitched roof.

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7. SUPPORTING STRUCTURE ASSEMBLING MANUAL

The standard kits are defined to install two PV Panels in portrait position.
(Figure 46)

When a Landscape installation is required needs an additional mounting kit. The final assembly will use a portrait mounting kit + a Landscape kit (available as an accessory kit). (Figure 47) The roof supports must be installed according to the distances presented in the table 9.

Figure 46. Standard Mounting kit for portrait installations

Table 9. Spacing between the roof supports Structure 2 PV Modules 2 PV Modules Portrait Landscape Anchors 4 8 X1 1300 1300 X2 580 950 X3 Y 800 520

Figure 47. Standard Mounting Kit + Landscape accesory for Landscape installations

The transverse profile is mounted to the roof supports using the hammer head stainless M10 nuts & bolts. (Figure 48)

Figure 48. Transverse profile mounting to the roof brackets

The mounting of the PV modules to the roof profiles is performed with clamps installed on the sides and in the centres of the modules. These are fixed using M8 nuts & bolts. (Figure 49, Figure 50)

Figure 49. PV module centre clamps

Figure 50. PV modules side clamps

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7. SUPPORTING STRUCTURE ASSEMBLING MANUAL

The plastic end caps supplied should be pressed into the transverse profile. (Figure 51)

Figure 51. End covers for the transverse profiles

The next figure shows a supporting structure for pitched roofs for 2 PV modules. (Figure 52)

Figure 52. Structure for 2 PV modules

To connect the transverse profiles together use a connection profile and fix with 2 hammer head stainless M10 nuts & bolts (supplied). (Figure 53)

Figure 53. Profile connectors

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8. WARRANTY
Standard warranty Terms & Conditions: PV Modules- 10 years Inverter- 5 years To receive your free warranty please complete the form supplied with the system within 30 days of installation, or simply call heateam, the service division of Baxi Heating UK Limited on 0844 879 7690 Our promise to you If you experience a fault with your new system, we aim to provide a safe and high quality repair service supported by our dedicated national network of highly skilled engineers. If your installer cant resolve the problem for you, we will do everything we can to get an engineer out to you as quickly as possible. Nothing in this warranty will affect your statutory consumer rights What you need to do if you experience a problem with your system. You should always contact your installer first because the fault may not be related to the system itself and he/she decides they cant repair it our friendly customer service team is on hand to help. Simply call our service division heateam on 0844 879 7690 to book an engineer visit or for any general advice that you may need. Our contact centre is open Monday to Friday 8 am- 8 pm, weekends and Bank Holidays 8.30am- 2pm, excluding Christmas Day and New Years Day. When calling heateam you must have the following information to hand: System serial number System model number Your installer name, address details and contact details Proof of purchase ( if you do not have the serial number) What this warranty convers Free of charge repair or replacament of components found to be faulty from manufacture. Free of charge replacement of the complete assemblies provided always that the failure ir related to a manufacturing fault that cannot be repaired or ir beyond repair. The warranty starts from the date your product is installed. What this warranty does not cover Collectors that are installed damaged or damaged during installation. If a Module is found to be damaged on delivery then it must not be installed, simply return it to your supplier for replacement under warranty. The warranty will become invalid if the failure is due to frost, transient voltages, lightning strikes or any act of vandalism or mis use. Tampering or modification will invalidate this warranty. The installation must be in an appropriate location. Due to the varied locations PV modules can be installed Baxi Heating UK Ltd will only carry out warranty repair/replacement to Modules which have safe access provided that meets current health & safety working at heights requirements. heateam will cover the cost of any safety equipment required to meet this standard after the first 30 days of installation up to l year and will appoint a contractor to carry this work out. Prior to this contact your installer. heateam accept no liability for any third party damage. Repairs to a system which havent been installed and commissioned properly, as set out in the installation and commissioning instructions. Any other defects or failures, either in the connected system or outside of the system itself. Installations within commercial settings for which this system was not designed. Reimbursement of any third party repair or replacement costs that we havent been told about and agreed you in advance. Compensation for consequential losses (e.g. loss of earnings, businees losses, stress and inconvenience) arising from a product breakdown, including repair delays caused by factors outside our reasonable control.

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9. MAINTENANCE
Operations Maintenance operations in a solar photovoltaic system are minimal. However, the following operations are recomended. 1. Clean the surface of the module when needed; the existence of dust on the module reduces significantly its performance; always use water (neutral) with a clean cloth or sponge; DO NOT use an abrasive solution. Clean only during early morning or late afternoon, when the levels of solar radiation are low, and the temperature of the modules is lower, to avoid thermal shocks that could damage the photovoltaic cells. Do not use pressurized water or steam cleaning materials, they may damage the surface of the modules. Avoid thermal shock in the modules, it can cause cracks in the cells; do not clean the modules with hot water when its temperature is too low or with cold water when its temperature is too high. Check the condition and integrity of electrical connections and mechanical components each semester. If you notice any abnormality in the installation, immediately contact a technician; do not attempt to resolve it; also, check the maintenance of other components of the installation, such as inverters, charge regulators, batteries, and others. Maintenance operations should be done only by qualified personnel.

2. 3. 4. 5. 6.

7.

Tests The following tests must be performed during maintenance processes. Checking the open circuit voltage (VOC) in each string of modules.

The value of the measured voltage, string open circuit voltage, should correspond to the sum of the individual open circuit voltage of all the modules on that string. If the measured value is much lower than expected, the string may have a problem. Checking the value of current (ISC) on each string of modules.

Measures can vary significantly depending on weather, time of the day and possible shading on the modules. Depending on the number of modules in series, if the voltage exceeds 30 VDC, take all precautionary measures to avoid the risk of electric shock.

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10. NOTES

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All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet. All goods are sold subject to our standard Conditions of Sale which are available on request.

Brooks House, Coventry Road, Warwick. CV34 4LL Technical Enquiries 0844 879 7690 Our contact centre is open Monday to Friday 8am to 6pm, Weekends and Bank Holidays 8.30am to 2pm. We are closed Christmas Day and New Years Day. Website www.baxi.co.uk

Registered Office: Baxi Heating UK Limited Brooks House, Coventry Road, Warwick, CV34 4LL, United Kingdom. Registered No: 03879156 VAT Reg No: 604 6658 37

SP Comp n 750152502a (01/12)

750152502